Cartons from mutually nestable blanks



Oct. 25, 1966 K. T. BUTTERY ETAL 3,281,053

CARTONS FROM MUTUALLY NESTABLE BLANKS am, Afef/mm Bay Oct. 25, 1966 K. T. BUTTRY ETAL 3,281,053

CARTONS FROM MUTUALLY NESTABLE BLANKS Filed June 16, 1965 5 Sheets-Sheet 2 LZz/ezz /0219 fenzeL/ Tazfefy ml /ofmfzz? Q Nucyezz Oct. 25, 1966 K. T. BUTTERY ETAL. 3,281,053

CARTONS FROM MUTUALLY NESTABLE BLANKS 5 Sheets-Sheet 3 Filed June 16, 1965 yen United States Patent Oil ice 3,281,053 Patented Oct. 25, 1966 3 281 053 CARTONS FROM MUTUAJLY NESTABLE BLANKS Kenneth T. Buttery and Norman A. Nuyen, Kalamazoo,

Mich., assignors, by mesne assignments, to Brown Company, a corporation of Delaware Filed June 16, 1965, Ser. No. 464,455 5 Claims. (Cl. 229-51) The present invention relates to cartons, and is more particularly concerned with cartons which may be readily `and inexpensively erected from integral cut and scored mutually nestable blanks, and which cartons may be readily and positively sealed by means of automatic machinery.

Cartons having a so-called flip-top cover hingedly connected to the edge of the rear panel, which may be erected with the cover in sealed condition and which may be readily opened by the removal of a tear strip, have become exceedingly popular, particularly as containers for food items such as ice cream. Once the tear strip is removed, the cover may be opened for access to some or all of the contents, and may be reclosed for further storage until the contents have been lcompletely consumed. Cartons of the type described which have been available in the prior art, although satisfactory in use, have the disadvantage that they are dicult to construct and seal on automatic machinery.

Prior art cartons are generally provided with an outer front wall member integral with the cover of the carton, having its own flaps extending at the ends thereof. A tear strip is provided as an integral unit and extends from the end of one outer front Wall flap, across the outer front wall, and to the end of the opposite outer front wall flap. Such a structure is expensive, difficult to construct into a carton from an integral blank, and requires expensive machinery for the purposes of erection and sealing. Additionally, such cartons require a greater amount of paperboard, thus adding to the material cost. For many purposes it is suicient for only the cover front wall to be provided with detachable means adhesively aflixing the cover to the front wall of the carton. Even where it is necessary for the cover end wall panels to be affixed, for most purposes aflixing the panels at limited zones is sui-licient.

Prior art cartons also have the disadvantage that, in order to heat-seal the outer end flaps to inner end flaps, it is often necessary for the heat to travel through the thickness of an intermediate ap, often resulting in improper .sealing Still a further disadvantage in prior art cartons is that, where it is not convenient to seal the outer end aps along their entire height, the end structure is somewhat weakened and the outer flaps at their unsealed edges have a tendency to curl outwardly, detracting from the appearance of the carton and additionally permitting the curled edges to catch on objects with which they come in contact and to become torn, disgured, or discolored. A further addition to material cost of prior art cartons results from the 'fact that they must be cut from a substantially rectangular blank. Consequently, there is no opportunity to nest adjacent blanks with each other to provide a saving in material cost.

It is an object of the present invention to provide cartons which may be formed from integral cut and scored mutually nestable blanks. `It is a further object to provide a top-opening carton which may be sealed by means of a detachable adhesive strip afllxing the cover to the front wall of the carton. It is another object to provide such a carton which may be readily reclosed when it is desired to store unconsumed contents. It is a `still further object to provide a carton of the type described which can be readily erected and subsequently sealed by means of relatively simple and inexpensive machinery. It is an additional object to provide a carton having its panels so contoured to facilitate assembling and heat sealing the various panels to form a strongly sealed carton. It is still an additional object to provide a carton the end panels of which may be heat-sealed with greater :facility than those cartons of the art where heat must travel through an intermediate flap in order to complete the sealing of the end aps. It is still a further object to provide means whereby the end panels of the carton cover may be aixed to the junction of the outer end flaps, thus serving a supplemental function in securing the outer end llaps together in addition to securing the cover end panels to the carton ends. The accomplishment of the foregoing and additional objects will become more fully apparent hereinafter.

The invention .in its preferred embodiment is illustrated by the accompanying drawings in which:

FIG. 1 is `a plan view of a blank cut and scored for assembling a carton according to the invention, additionally showing a portion of an adjacent nesting blank.

FIG. 2 is a plan view of the blank folded over and glued to form a flattened tube.

FIG. 3 is an end view of the carton with several of the flaps folded into position.

FIG. 4 is a perspective view of the sealed carton; and

FIG. 5 is a perspective view of the carton of FIG. 4 after the seal has been broken and the cover opened.

According to the invention, a carton is provided having panels including a bottom member having a pair of inner end wall flaps hingedly connected to the ends thereof a front wall member hingedly connected to an edge of the bottom member having front wall outer end ilaps hingedly connected to the ends thereof, and a rear wall member hingedly connected to the other edge of the bottom member having rear wall outer end flaps hingedly connected to the ends thereof. The rear wall outer end flaps, the cover end wall ilaps, and the cover front wall end flaps are designed to be shorter than the front wall outer end ilaps or the inner end wall flaps. Additionally, the upper terminal corner of each rear wall outer end ap is provided wit'h a rectangular recess or cut-out so designed that when adjacent blanks are nested together in opposite directions with the rear Wall outer end flaps in edge-to-edge engagement, the edges of the rear upper corner of the inner end wall flap of one blank are nested in edge-to-edge engagement with the edges of the upper terminal corner recess of the rear wall outer end ap of the other blank. In a preferred embodiment, the lower terminal corners of the rear wall outer end flap are also provided with a preferably rectangular recess or cut-out having its vertical edge substantially colinear with that of the upper terminal corner recess. The front wall outer end flaps are dimensioned so that they may be folded over and affixed to the rear wall outer end ilaps with their terminal edges substantially in engagement with the vertical or rear edges of both recesses. The lower corner of the front wall outer end ilap may be directly adhesively aflxed to the inner end wall flap through the lower terminal recess 0f the rear wall outer end flap Where such structure is utilized. A cover is also provided which is hngedly connected to the upper edge of the rear wall member. The cover is provided with cover flaps comprising cover end wall panels and a cover front wall panel. Detachable means, as for example an adhesive strip, lis allixed to the edge of the cover front Wall panel at a severance line or by a tear strip, adhesively aixing the cover front wall panel to the front wall member. Additionally, the lcover end wall panels are each provided with a `detachable adhesive panel connected thereto at a severance line. When the carton is sealed, the adhesive panel is alXed to both the front wall outer end ilap and the rear wall outer end flap at the line of engagement between the upper portion of the terminal edge of the front Wall outer end flap and thel vertical edge of the recess of the rear wall outer end flap.. As a result, the adhesive panel serves the dual function' of securing'the'cover end wall panels to the end portion of the carton proper, and additionally securing the upper edges of the front wall outer end ap and rear wall outer end liap together to form a strong sealed carton.

Reference is now madeto the accompanying drawings for a better understanding of the invention, wherein all of the parts are numbered, wherein the same numbers are used to refer to corresponding parts throughout, and wherein areas havingy an adhesive applied thereto are indicated by' stippled shading. In a preferred form, the carton of the invention is constructed from an integral blank, `as illustrated in FIG. 1, and comprises a bottom panel member 1, a front wall member 2, and a rear wall member 3 hingedly connected to the bottom member 1. A cover'4 is hingedly connected to the rear wall member 3. The bottom 1 is provided at its end with inner end Wall flaps 5 hingedly connected thereto, the front wall member 2 is provided at its ends with front wall outer end flaps 6 hingedly connected thereto, and the rear wall member 3 is provided with rear wall outer end flaps 7 hingedly connected thereto.

The cover 4 is provided with end flaps 8 comprising cover end wall panels 9 and adhesive panels 10 connected to the panels 9 at severance or fracture lines 11. As shown, the lower edges of the adhesive panels 10 extend below the edges of the cover end Wall panels 9. However, the adhesive panels may be designed, if desired, so that their lower edges are flush with, or even recede from, the line delined by the edges of the cover end wall panel 9. The cover 4 is provided at its forward edge with a cover flap 12 comprising a cover front wall panel 13, parallel severance or fracture lines 14 defining a tear strip 15 having a tab 16 at one end thereof and detachably connecting the cover front wall panel 13 t0 an adhesive strip 17 affixed to the front wall member 2. The cover front wall panel 13 is also provided at its ends with end liaps 18 for being adhesively afiixed to the cover end wall panels. The flaps 7 and 18 at the ends of the rear wall member and cover are so designed that they are shorter than the end flaps 5 and 6 of the bottom 1 and front Wall panel 2. Addition-ally, rear wall outer end ap 7 is provided with an upper terminal corner recess 20 of substantially rectangular contour. Consequently, adjacent blanks may berarranged in opposite directions and may be nested together with the edges of the rear upper corner of the inner end wall flap 5 of one blank in edge-to-edge engagement with the edges of the upper terminal corner recess 20 of the rear wall outer end tiap 7 of the other blank, as shown in FIG. l.

Therear` Wall outer end flaps 7 are also provided with lower terminal corner recesses 19 in the preferred ernbodiment shown. As a consequence, when the front 'wall outer end liaps 6 are folded thereover, they may be adhesively aliixed directly to the inner end wall flap 5 through the recess 19.

In assembling the carton, the carton 'blank may be folded at the score line between the bottom 1 and the rear wall member 3. The cover front wall panel 13 is then folded lover and the adhesive strip 17 aixed to the outer surface of the front wall member 2, forming a folded tube, as shown in FIG. 2. Alternatively, the front wall member 2 may be folded over at the score line connecting it with the bottom 1, and the adhsive strip 17 may then be glued to the outer surface of the front wall member 2 in the same manner. In either form the carton so folded occupies very little space,V and may be shipped to the packager in this form for filling and sealmg.

.To erect the carton further for filling, the folded carton is squared up, as on a conventional squaring machine.

One end is then closed by first folding in the inner end wall liap 5. The rear wall outer end ap 7 is then folded over, and the front wall outer end vflap 6 folded over and caused to overlap at least the forward portion of the rear wall outer end flap 7. The cover front wall panel ap 18 is then Ifolded over, followed finally by folding over the cover end wall panel 9. Heat is applied to soften the adhesive, causing the front wall outer end flap 6 to become adhesively affixed to the rear wall outer end flap 7 and also to the inner end wall flap S through the corner recess 19. The adhesive panel 10 which now overlaps both the front wall outer end iiap and rear wall outer end flap 7 at the line of engagement between the two iiaps, becomes adhesively alixed to both end tiaps, also securing the cover end Wall panel. Flap 18 becomes aixed to cover end Wall panel 9. The carton may then be filled through the end remaining open. The open end may subsequently be closed and sealed in the same manner, to form a completely sealed carton as shown in FIG. 4. Alternatively, the first carton end may be closed and/or tacked, as with glue, but not sealed, and then both carton ends sealed concurrently or simultaneously after lling of the carton.

The carton may be opened by grasping the tab 16 and removing the tear strip 15. As the cover is then lifted open, the cover end wall panels 9 are parted from the adhesive panels 10 at the severance line 11, to form the structureV shown in FIG. 5. The cover may be reclosed for storing unconsumed contents.

Although the embodiment illustrated and described utilizes a tear strip for detaching the cover front Wall panel from the adhesive strip, in another embodiment an adhesive strip may be utilized which is directly connected to the cover front wall panel at a severance line, and which adhesive strip is preferably aixed to the front wall 2 at spaced-apart .adhesive areas. The .front Wall 2 may be provided with :cut scores surrounding the adhesive areas to prevent the surface of the front wall from becoming torn When the adhesive strip is removed. In a further improved embodiment, transverse cuts may also be provided in the adhesive strip intermediate the adhesive tareas to facilitate removal of the adhesive strip. The severance lines in lany embodiment may have any desired configuration, such as spacedepart slits, V- shaped slits, or combinations of slits and cuts of any configuration.

It is thus seen that an economical and conveniently erected and sealed carton of sufficient durability for frequent opening and r`eelcising is produced, which carton is produced from an integral blank so designed that adjacent blanks may be oriented for close mutual nesting to provide an appreciable saving in cost of raw material, and whereby all of the other objects of the invention are attained.

Although the invention has been described primarily as it would be practiced when a heat-sealable adhesive is carried directly on the carton blank, other types and forms of adhesive and other means of applying the adhesive to effect sealing of the carton may be employed.

Plastic (such as polyethylene) coated or wax coated paperboard, or laminated paperboard with openings for extrusion sealing, may also be employed for the cartons and carton blanks according to the invention.

It should be understood that the invention is not limited lto the exact details of construction, operation, or exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art, and the invention is therefore to be limited only by the scope of the appended claims.

Y We claim:

. 1. A carton formed of an integral blank cut and scored to provide a bottom member having inner end wall flaps hingedly connected to the ends thereof, a front wall member hingedly 'connected to one edge of said bottom member having front wall outer end aps hingedly connected to the ends thereof, and a rear Wall member hingedly connected to the other edge of said bottom member having rear wall outer end flaps hingedly connected to the ends thereof, at least the upper portion of the vertical edges of the front and rear wall outer end aps at each end of said carton being in edge to edge engagement, a cover hingedly connected to the upper edge of said rear wall member provided with cover flaps comprising cover end wall panels and a cover front wall panel, detachable means adhesively atiixing said cover front wall panel to said front wall member, and an adhesive panel detachably connected to each of said cover end wall panels and adhesively axed to both said front wall outer end aps and said rear wall outer end flaps at the line of engagement between the vertical edges thereof.

2. An integral blank for forming a carton cut and scored to provide a bottom member having inner end wall aps hingedly connected to the ends thereof, a front wall member hingedly -connected to -one edge of said bottom member having front wall outer end flaps hingedly connected to the ends thereof, and a rear wall member hingedly connected to the other edge of said bottom member having rear wall outer end flaps hingedly connected to the ends thereof, at least the upper portion of the vertical edges of the front and rear wall outer end flaps at each end of said carton being adapted to be folded into edge to edge engagement, a cover hingedly connected to the upper edge of said rear Wall member provided with cover flaps comprising cover end wall panels and a cover front wall panel, detachable means adapted for adhesively aiixing said cover front Wall panel to said front wall member, and an adhesive panel detachably connected to each of said cover end wall panels and adapted to be adhesively aixed t-o both said front wall outer end aps and said rear wall outer end aps at the line of engagement between the vertical edges thereof.

3. An integral blank for forming a carton cut and scored to provide a bottom member having inner end wall aps hingedly connected to the ends thereof, a front wall member hingedly connected to one edge of said bottom member having front wall outer end aps hingedly connected to the ends thereof, a rear wall member hingedly connected to the other edge of said bottom member having rear Wall outer end flaps hingedly connected to the ends thereof, and a cover hingedly connected to the upper edge of said rear wall member provided with cover flaps comprising cover end wall panels and a cover front wall panel having end aps adapted to be adhesively aixed to said cover end Wall panels, said rear wall outer end aps, said cover end Wall panels, and the end aps of said cover front Wall panel being shorter than said front wall outer end iiaps and said inner end wall aps, the upper terminal corner of each rear wall outer end flap being provided with a recess so designed that when adjacent blanks are nested together in opposite directions the edges of the rear upper corner of the inner end wall liap of one blank `are nested in substantially edge-to-edge engagement with the edges of the corner recess of the rear wall outer end flap of another blank, detachable means adapted for adhesively aixing said cover front wall panel to said front wall member, and an adhesive panel at each end of said carton detachably connected to said cover end wall panels and adapted to be adhesively affixed to both said front and said rear Wall outer end aps.

4. A-n integral blank for forming a carton cut and scored to provide 4a bottom member having inner end wall flaps hingedly connected to the ends thereof, a front Wall member hingedly connected to one edge of said bottom member having front Wall outer end aps hingedly connected :to the ends thereof, a rear wall member hingedly connected to the other edge of said bottom member having rear wall outer end flaps hingedly connected to the ends thereof, and a cover hingedly connected to the upper edge Iof said rear wall member provided with cover flaps comprising cover end wall panels and a cover front Wall panel having end flaps adapted to be adhesively affixed to said cover end wall panels, said rear wall outer end aps, said cover end wall panels, and the end aps of said cover front Wall panel being shorter than said front wall outer end aps and said inner end wall flaps, the upper terminal corner of each rear wall outer end ap being provided with a rectangular recess so designed that when adjacent blanks are nested .together in opposite directions the edges of the rear upper corner of the inner end wall flap of `one blank are nested in edge-to-edge engagement with the edges of the corner recess of the rear wall outer end flap of another blank, said fron-t wall outer end flaps overlapping and adapted to be adhesively aixed to said rear Wall outer end flaps, detachable imeans adapted for adhesively -aixing said cover front wall panel to said front wa-ll member, and an adhesive panel at each end of said carton detachably connected to said cover end wall panels and adapted to be adhesively aflixed to both said front and said rear wall outer end aps.

5. The carton of claim 1, wherein said upper terminal corner of each rear wall outer end flap is provided with a recess.

References Cited by the Examiner UNITED STATES PATENTS 2,329,628 9/1943 Lanigan 229-37 3,109,577 11/ 1963 Knipp 229-51 3,125,280 3/1964 Henry 229-51 3,144,980 8/1964 Larson 229-51 3,146,936 9/1964 Hodapp 229-51 3,197,114 7/ 1965 Holmes 229-51 JOSEPH R. LECLAIR, Primary Examiner. DAVID M, BOCKENEK, Examiner, 

1. A CARTON FORMED OF AN INTEGRAL BLANK CUT AND SCORED TO PROVIDE A BOTTOM MEMBER HAVING INNER END WALL FLAPS HINGEDLY CONNECTED TO THE ENDS THEREOF, A FRONT WALL MEMBER HINGEDLY CONNECTED TO ONE EDGE OF SAID BOTTOM MEMBER HAVING FRONT WALL OUTER END FLAPS HINGEDLY CONNECTED TO THE ENDS THEREOF, AND A REAR WALL MEMBER HINGEDLY CONNECTED TO THE OTHER EDGE OF SAID BOTTOM MEMBER HAVING REAR WALL OUTER END FLAPS HINGEDLY CONNECTED TO THE ENDS THEREOF, AT LEAST THE UPPER PORTION OF THE VERTICAL EDGES OF THE FRONT AND REAR WALL OUTER END FLAPS AT EACH END OF SAID CARTON BEING IN EDGE TO EDGE ENGAGEMENT, A COVER HINGEDLY CONNECTED TO THE UPPER EDGE OF SAID REAR WALL MEMBER PROVIDED WITH COVER FLAPS COMPRISING COVER END WALL PANELS AND A COVER FRONT WALL PANEL, DETACHABLE MEANS ADHESIVELY AFFIXING SAID COVER FRONT WALL PANEL TO SAID FRONT WALL MEMBER, AND AN ADHESIVE PANEL DETACHABLY CONNECTED TO EACH OF SAID COVER END WALL PANELS AND ADHESIVELY AFFIXED TO BOTH SAID FRONT WALL OUTER END FLAPS AND SAID REAR WALL OUTER END FLAPS AT THE LINE OF ENGAGEMENT BETWEEN THE VERTICAL EDGES THEREOF. 